ZnO varistors are widely used to protect power apparatuses,

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1 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 3, JULY Discussions on Nonuniformity of Energy Absorption Capabilities of ZnO Varistors Jin-Liang He, Senior Member, IEEE, and Jun Hu Abstract The energy absorption capability is a key parameter for ZnO varistors. This paper discusses the nonuniformity of energy absorption capabilities of ZnO varistors. With experiment results, we show that energy absorption capabilities of ZnO varistors can be highly scattered, for different commercial varistors, and for the same varistors under diverse current waves. We explain this nonuniformity phenomenon through numerical simulations, based on the microscopic circuit and heat transfer models of ZnO varistors. How the applied current, the nonuniformity of microstructure, and the nonuniformity of microstructural electrical and thermophysical characteristics influence the energy absorption capabilities of ZnO varistors is also analyzed. Index Terms Current concentration, energy absorption capability, impulse current, nonuniformity, ZnO varistor. I. INTRODUCTION ZnO varistors are widely used to protect power apparatuses, electronic devices, or systems from dangerous surges. In a power system, ZnO varistors in surge arresters are required to absorb substantial amounts of energy resulting from temporary overvoltages, switching surges, or discharges of lightnings. Therefore, their energy absorption capabilities are crucial for the integrity of equipment and systems. However, it has been observed in experiments that differences in barrier voltages, grain sizes, and grain boundary characteristics inside the same ZnO varistor and among different ZnO varistors can cause nonuniformity in the microstructural electrical and thermophysical characteristics of ZnO varistors, and finally result in the nonuniformities of their current handling capabilities and energy absorption capabilities. In high-voltage systems, ZnO varistors of large sizes are needed to decrease the system insulation level. However, the nonuniformity of electrical and thermophysical characteristics caused by grain sizes, barrier voltages, and other factors, will become a much more serious problem, as the size of ZnO varistors increase, which leads to the reduction of their energy absorption capabilities. Measurements of and discussions on the energy absorption capabilities of ZnO varistors have been reported in [1] [8]. The energy absorption capability of ZnO varistor is limited by its failure situation. Three failure modes have been identified thus far [9]: electrical puncture, physical cracking, and Manuscript received May 2, 2006; revised November 3, This work was supported by the National Natural Science Foundation of China under Grants and Paper no. PWRD The authors are with the State Key Lab of Power Systems, Department of Electrical Engineering, Tsinghua University, Beijing , China ( hejl@tsinghua.edu.cn). Digital Object Identifier /TPWRD thermal runaway. Thermal runaway is related to current and voltage instability, while physical cracking is due to huge thermal stresses, and electrical puncture is caused by current concentration. The puncture phenomenon was simulated by Eda [1], while Bartkowiak et al. [10] simulated the puncture and cracking phenomena. Their proposed models can be used to simulate the thermo-mechanical behavior of various types of metal-oxide varistor disks and to estimate their energy handling capabilities without performing destructive experiments. The influence of the microstructural electrical nonuniformity of varistor disk on its current localization and energy handling capability was also presented in their work. In this paper, we aim to discuss the nonuniformity of the energy absorption capabilities of ZnO varistors, based on both experiments and simulations. II. EXPERIMENTS AND SCATTERED DESTRUCTION PHENOMENA The primary functionality of ZnO varistors is to protect electrical devices and systems, by discharging transient surges and limiting overvoltages. The energy absorption capability is the second most important property of ZnO varistors next to nonlinearity [9]. The absorbed energy by ZnO varistor can be expressed as where is the voltage applied on the varistor, is the current through it, and is the time duration that the current is applied. The energy absorption capability is usually referred to as the permitted energy absorbed by per unit volume of a varistor, measured in. Generally, the permitted energy is defined as the maximum amount of energy that a varistor disk can absorb before it fails. In other words, the permitted energy indicates the point at which varistor failure happens. In our experiments, we applied 50-Hz ac power frequency current and impulse currents on commercial ZnO varistors, for various time durations. The currents through ZnO varistors and the voltages applied on them were recorded, so the energies absorbed by ZnO varistors could be calculated. Two types of commercial disk-shape varistors of different sizes were tested: type A with a diameter of 32 mm and a height of 10 mm, and type B with a diameter of 52 mm and a height of 10 mm. When varistors were tested under the conditions listed in Table I, they showed different distributions of failure modes, as illustrated in Fig. 1. The puncture destruction was dominant when low impulse currents were applied for long time durations, while the cracking destruction preponderates under high (1) /$ IEEE

2 1524 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 3, JULY 2007 TABLE I TEST CONDITIONS FOR IMPULSE DESTRUCTION PHENOMENA OF ZnO VARISTORS TABLE II TESTED ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS also transfer heat to the surroundings. Due to current concentration, the temperature of the region with more current will increase quickly. Since the grain boundary is dominated by whose melting temperature is around 820, when the temperature exceeds the melting temperature of grain boundary, the grain boundaries are melted to form a punctured hole through the ZnO varistor. III. NONUNIFORMITY OF ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS Fig. 1. Destruction ratios of ZnO varistors. impulse currents with short time duration. These phenomena are similar to the results obtained by Eda [1], although there are a few differences. In Eda s experimental results, most ZnO varistors of small sizes ended up with puncture destruction, when low impulse currents were applied for long time durations, and almost all failures were cracking destruction under high-impulse currents with short time duration. However, in our experiments on commercial ZnO varistor disks of large sizes, cracking destruction also occurred under low-impulse currents with long time duration, and puncture destruction also took place under high impulse currents with short time duration although in both cases, the other failure mode still dominated. In our experiments, the proportions of dominating failure modes are quite different between two types of varistors, and when different currents were applied. Cracking destruction reached about 50% and 75 under the 2-ms square-wave current, while puncture destruction reached about 90% and 60 under the 8-ms square- wave current. The puncture and cracking failures of ZnO varistors are caused by the current concentration phenomenon, which is due to the nonuniformities of microstructural electrical characteristics and absorbed energies in different parts of the varistor. Applying different currents would lead to different failure phenomena. When a high current is applied to a ZnO varistor for a short time, the energy is quickly injected into the ZnO varistor and triggers a thermal-insulated temperature rise process. The temperature gradients exist between different portions inside the varistor, which causes thermal stresses on the grain boundaries between ZnO grains. If the thermal stresses between different portions inside the varistor exceed the critic value, cracking destruction happens. However, when a small current is applied to a ZnO varistor for a long duration, heat conduction takes place between different portions of the varistor, and the surface of varistor will A. Influence of Applied Current Wave-Form on the Energy Absorption Capability Our experiments also show that the energy absorption capability is directly related to the current waves applied. We measured the energy absorption capabilities of type-a varistors with diverse types of current waves, which are shown in Table II. The relationship between energy absorption capability and duration of current is plotted in Fig. 1, which appears as a -shaped curve, with values in the middle lower than those on both ends. The black line in the figure indicates the average values of experiments under the same condition, and the dotted lines indicate the respective upper and lower bounds. The energy absorption capability of the ZnO varistor has a complex dependence upon the magnitude and the duration of the impulse current applied. As discussed by Sakshaug et al. [2], the energy absorption capability decreases with the increment of the current, and then it increases again if the current becomes very high and the impulse duration becomes very short. This is similar to our results shown in Fig. 2, which reveals that the energy absorption capability reaches its minimum when the pulse duration is about 1 ms. If the time duration is less than this pulse duration, the energy absorption capability decreases with the increase of the time duration, and when the time duration is longer than this pulse duration, the energy absorption capability increases continually. Such results are also accordant to the published conclusion that the tested energy absorption capabilities of ZnO varistors increase with the pulse width when it is in the range from 2 ms to 577 s [8]. Besides, the relationship between the energy absorption capability and the current density is shown in Fig. 3, which is highly scattered and -shaped as well. When a small current is applied to a ZnO varistor for a long time duration, its energy absorption capability is very high. Under such condition, the generated heat in one portion of varistor could be uniformly conducted to the whole varistor, so the possibility of overheat in one part is very low, and the energy needed for causing the varistor destruction would be high. When a large current is applied to a varistor for a

3 HE AND HU: DISCUSSIONS ON NONUNIFORMITY OF ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS 1525 Fig. 4. Energy-absorption capabilities of ZnO varistors of different sizes. Fig. 2. Relationship between the energy absorption capability and the time duration of applied current. Fig. 3. Relationship between the energy absorption capability and the current density of applied current. very short time, its energy absorption capability would be high, too. It is believed that ZnO varistors can hardly be destructed in such short time duration, therefore, they present high energy-absorption capabilities. From Figs. 2 and 3, the nonuniformity of energy absorption capabilities among different varistors is very obvious when a small current is applied for a long time duration, although it is mitigated when a large current is applied for a short time. From Table II, the ratio between the maximum and minimum energy absorption capabilities is 1.56 when 50-Hz ac current is applied, which indicates that the energy absorption capabilities are very nonuniform. But when an 8/20 impulse current is applied, this ratio is only 1.08, showing the energy absorption capabilities are fairly uniform. B. Influence of Varistor Cross-Sectional Area on the Energy Absorption Capability ZnO varistor is a kind of sintered polycrystalline ceramic, formed by a large number of ZnO grains and grain boundaries in parallel and in series. The impulse energy absorption capabilities of ZnO varistors are dependent on their microstructures [1], [7]. Generally, we would think that a thicker varistor should have a higher threshold voltage, and a varistor with a larger cross-sectional area could absorb more energy proportionally. But actually, the sintered polycrystalline ceramic is not uniform in microstructure, so that the energy absorption capability does not increase linearly with its cross-sectional area. The test results state that the deviation of the destruction energy is more pronounced for varistor with larger cross-sectional area, while the energy absorption capability per unit volume decreases accordingly. We tested two types of commercial disk-shaped ZnO varistors, which had the same additives and were sintered in the same technique. Their diameters were 52 and 32 mm, respectively, and their thicknesses were 10 mm. The square-wave current with 2 ms time duration was applied to the varistors, and their energy absorption capabilities were 216 and 271 on average, as shown in Fig. 4. Obviously, the energy-absorption capability per unit volume of ZnO varistor decreases when its cross-sectional area increases. The larger the cross-sectional area of the ZnO varistor is, the smaller its energy-absorption capability is. IV. PHENOMENON EXPLANATION OF ENERGY ABSORPTION NONUNIFORMITY BY NUMERICAL SIMULATION As discussed in many papers ([1], [3], [4], [10]), the energy absorption capability of the ZnO varistor is related to the failure modes, which are triggered by not only the applied current waveform, but also the microstructural electrical and thermophysical characteristics. The original intrinsic reason of the different ZnO varistor failure modes and the nonuniformity of their energy absorption capabilities observed in our experiments is the nonuniformity of their microstructures, and the nonuniformity of their microstructural electrical and thermophysical properties. A. Nonuniformity of ZnO Varistors in Microstructure As analyzed in [11], chaotic phenomena exist in the microstructural characteristics of ZnO varistors. It states that the nonuniformity of microstructural characteristics of ZnO varistors is an original property. This chaotic property leads

4 1526 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 3, JULY 2007 to the intrinsic behavior of nonuniformity of global electrical characteristics caused by microstructures of ZnO varistors. The nonuniformity of electrical parameters exists in different ZnO varistors, which was analyzed statistically in [12]. Even in the same ZnO varistor, electrical parameters in different portions are not uniform. Many researchers have measured the barrier voltages of single grain-boundaries in ZnO varistors using different methods [14] [16], [19], [20]. The measured barrier voltages ranged between 1.6 V and 6.0 V [14], showing high nonuniformity. The nonuniformity of electrical characteristics of grain boundaries in ZnO varistors was systematically analyzed in [13]. The microcontact electrical measurements on multiple-phase ZnO varistors show a wide diversity of grain-boundary characteristics, and reveal that different single grain boundary has different electrical characteristic in the same varistor. The barrier voltages have normal distributions, and only a few grain boundaries are electrically active. According to the measured results [14] [18] about electrical characteristics of grain boundaries, the grain boundaries can be simply classified into three representative types: good and bad nonlinear microjunctions, and ohmic microjunction. The good microjunction has high leakage resistance and high nonlinearity coefficient, while the bad microjunction has two to three orders of magnitude lower leakage resistance and much lower nonlinearity coefficient (about 10) [15] [17]. The ohmic grain-boundary is called ineffective grain-boundary, which leads to the existence of shortcut pathway inside ZnO varistors [19]. Then, it is not difficult to understand that the nonuniformity exists in global electrical parameters, such as 1 ma DC voltages (the respective voltage when a 1-mA dc current through a ZnO varistor) and the impulse residual voltages among different ZnO varistors or different portions inside a ZnO varistor. For instance, Hohenberger et al. [21] observed the nonuniformity of 1-mA voltages from different regions on the surface of the ZnO varistor by a special method. B. Simulation Model It is already well known that the current localization phenomenon of ZnO varistors is a crucial factor for their energy absorption capabilities. Such current localization phenomenon is mainly due to the nonuniformities of microstructures and electrical characteristics of ZnO varistors, such as grain sizes and barrier voltages. The Voronoi network can effectively simulate the microstructures of ZnO varistors, and model the connecting effect of ZnO grains and grain boundaries in the whole network. Bartkowiak et al. [22] were the first to describe the electrical properties of the ZnO varistor polycrystal using a two dimensional Voronoi network model. In this paper, the 2-D Voronoi network is also used to simulate the microstructure of a single film of ZnO varistor polycrystal. As shown in Fig. 5, each polygon represents a ZnO grain, and each edge of the polygon shared by adjacent polygon corresponds to their grain boundary. When the thickness varies, the corresponding microstructure represents ZnO varistor polycrystal of different average grain size. Similarly, the varied disorder degree can represent ZnO varistor polycrystal with different uniformity of gain sizes. Fig. 5. Simulation of the grains and their connections in the ZnO varistor. Then, the electrical relations among the grains can be deduced following the Voronoi network model. If there is a shared edge between two polygons, a nonlinear resistor is used to simulate the electrical relation between them. The inner of a polygon is considered as an ideal conductor. The current through the grain boundary between grains and is assumed to be proportional to the area of the grain boundary. The current density flowing from grain to grain is determined by where, is the current density, ; is the voltage of grain, is the voltage of grain ; and. and are constants, ; is a constant,. is the prebreakdown resistivity,, and is the resistivity in the upturn region,. is the barrier height, which equals 0.8 ev. is a constant related to electrical characteristic and geometrical structure of intergranular layer of ZnO varistors, where is the electron charge, is the permittivity of free space,, is the relative dielectric constant of the intergranular layer, which is in the range from 4 to 25 ( is selected in this calculation), and is the thickness of the intergranular layer in ZnO varistors, whose actual value is about Sowe can obtain. is Boltzmann s constant,. is the temperature, K, and is the barrier voltage of the grain boundary. is the nonlinear coefficient. In our study, the values of different nonlinear resistors are not equal, but follow a statistical distribution to describe the nonuniformity of the electrical characteristics of the grain boundaries as given in [13]. is the upturn voltage,, where, is the upturn current. The values of these parameters are changed in the program to simulate different ZnO varistors with different (2)

5 HE AND HU: DISCUSSIONS ON NONUNIFORMITY OF ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS 1527 Fig. 6. Basic structure of heat transfer model. microstructures or different electrical characteristics of grain boundaries. The external voltage is applied between the top and bottom edges of the Voronoi network, i.e. the potential of the top edge is, and that of the bottom edge is 0. The node voltage equations of the circuit can be deduced according to the Kirchhoff s Law. So we obtain where is the vector, and is the length of the common edge between the polygon and polygon. If grain is not a neighbor grain of grain, then. The grain voltages in (3) can be derived iteratively. Then the current passing through every edge can be calculated according to (2). Thus, the current distribution on the Voronoi network is acquired. The heat transfer inside the ZnO varistor is considered when it is injected with a surge current, typically, the square wave current. The finite difference method is used to calculate the temperature and thermal stress distributions inside ZnO varistors. First, every polygon in Voronoi network is divided into several triangle elements, as the imaginary lines shown in Fig. 6, according to the number of the edges of each polygon. Every element uniquely is determined by a polygon edge and the center of the polygon. So for every element, there are three other triangle elements adjacent to it. It is supposed the average temperature of the element is and its original value is the room temperature. The heat transferring into the element during the time duration is determined by where is the temperature of the adjacent element, is the length of the common edge of two adjacent elements, is the distance between the centers of the two adjacent elements, and is the thermal conductivity of the ZnO varistor,. Out of three edges of the triangle, only one belongs to the polygon, i.e., a grain boundary. So there is Joule heat power consumption on this edge when a current passes through it, and can be calculated according to the current through this grain (3) (4) Fig. 7. Simulated current localization phenomena (the gray-level spectrum from white to black represents the relative value of the current passing through a grain. The darker the color in a grain is, the more current passes through the grain). boundary as discussed above. Then, the temperature rise of the element can be calculated as where is the area of the triangle element, is the thickness of the simulated ZnO varistor, is the mass density of the ZnO varistor,, and is the thermal capacity of ZnO varistor, [23]. Using this heat transfer model, the temperature of the element can be calculated following the finite difference method. If the temperatures of two adjacent triangles are and respectively, the thermal stress between them would be [24] where is Young s module of elasticity, is the linear expansion coefficient, and is Poisson s ratio. The selected parameters are,, and [25]. A more detailed description of the simulation can be found in [26]. C. Influence of Applied Current on Energy Absorption Capability As observed from the experimental results in Fig. 3, the current applied on a ZnO varistor has a dominant influence on its energy absorption capability. The current concentration phenomenon is of crucial importance on such results. Experimentally, the nonuniform current distribution was detected by adding small spot electrodes on the surfaces of varistor disks [10], by using infrared thermo-cameras [27] and by electroplating (galvanic) techniques [21]. The current localization phenomena of ZnO varistors could be easily observed from the simulation results as shown in Fig. 7, when good and bad grain boundaries exist in ZnO varistors in an arbitrary distribution. The current through the ZnO varistor could be easily changed by adjusting the voltage applied. The extent of current localization is quite diverse under varied voltage. When the applied voltage is very small (the respective current is small), the current distribution inside the ZnO varistor is uniform. It is difficult to generate the current (5) (6)

6 1528 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 3, JULY 2007 Fig. 9. Simulated thermal stress distribution inside a ZnO varistor. Fig. 8. Simulated temperature distribution inside a ZnO varistor. concentration phenomenon, so the energy absorption capability of ZnO varistor is high. When the applied voltage increases (the respective current increases), the current paths become less. When the applied voltage is 2700 V/cm, there are only two obvious current localization paths observed. Most amount of the applied current flows through these two narrow paths, so the current concentration is very serious. Then, the energy absorption capability becomes small with the increment of the applied current. Subsequent to the increment of the voltage applied, the current concentration paths increase instead. When the applied voltage is 3900 V/cm, there are many current concentration paths observed again. Thus, the energy absorption capability enhances with the increment of the current applied. Such varied phenomena of the current distributions in Fig. 7 are well fit to explain the -shape curve between the energy absorption capability and the applied current as shown in Fig. 3. Furthermore, the temperature rise of each element can be calculated by (4) and (5). After the voltage is applied for 2 ms, the temperature distribution in the model is shown in Fig. 8. The color lightness of each grain represents its temperature value: the lighter the color is, the higher the temperature is. Obviously in our simulated results, the temperature of the region with concentrated current is always much higher than else regions, forming a path penetrating from the top to the bottom. The average temperature rise in this case is 153 K, while the highest temperature rise reaches 376 K, and the lowest temperature rise is only 22 K. If the temperature of any high temperature region in the ceramic body exceeds 820, it would be melted, which leads to a very small penetrating hole. Thus, a puncture failure occurs. After the temperature distribution has been solved, the thermal stress between any two adjacent elements can be calculated by (6). The thermal stress distribution respective to the temperature distribution in Fig. 8 is shown in Fig. 9, in which the color lightness represents the value of thermal stress: the darker the color is, the higher the thermal stress is. The closer the region is to the current concentration path, the tenser the thermal stress is. In Fig. 9, the maximum tensest thermal stress reaches 32 MPa. When it exceeds the critical Fig. 10. Current localization ratios of ZnO varistors with different disorder degrees. thermal stress, the ZnO varistor ceramics would crack. Thus, a cracking failure occurs. D. Influence of Microstructural Nonuniformity on Energy Absorption Capability The disorder degree is used to simulate the nonuniformity of ZnO varistor microstructure. If the disorder degree is zero, the microstructure of the ZnO varistor is uniform. With the increment of the disorder degree of the ZnO varistor, the microstructure of ZnO varistor becomes more nonuniform. When the disorder degree is larger than 3, the generated Voronoi network is very similar to the actual microstructures of ZnO varistors. Fig. 10 describes the current localization ratios of ZnO varistors with different disorder degrees under the same applied voltage. Here, the current localization ratio is defined to represent the diversity of the current localization phenomena, where is the maximum value of the current density inside ZnO varistor and is the average value of. With the increment of the disorder degree, the current concentration phenomenon becomes more serious. When the ZnO varistor is uniform (the disorder degree ), the respective current localization ratio is about 11, and when the disorder degree is 5, the respective ratio reaches about 33. So, the more nonuniform the microstructure of the ZnO varistor

7 HE AND HU: DISCUSSIONS ON NONUNIFORMITY OF ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS 1529 Fig. 11. Current localization ratios of ZnO varistors with distributed barrier voltage varied. is, the more serious the current localization ratio is, and the smaller the respective energy absorption capability would be. E. Influence of Electrical Nonuniformity in Microstructure on Energy Absorption Capability Another metric that accounts for the nonuniformity of the ZnO varistor in microstructure is the nonuniformity of electrical characteristics of grain boundaries. One of the important parameters in the physical models of ZnO varistors explaining the transition phenomena from the low-current region to the high-current region is the value of the barrier voltage, which refers to the breakdown voltage per grain boundary barrier. As discussed in [13], the barrier voltage has a normal distribution, and its average value by direct measures is 3.3 V. When the standard deviation of the barrier voltage is changed, Fig. 11 shows the current localization ratios of ZnO varistors with distributed barrier voltage variances under the same voltage applied. With the standard deviation of the barrier voltage increases, the current localization ratio arises. When the standard deviation of the barrier voltage is 1.6 V, the reaches about 30, so the current localization is very serious, and the varistor would fail easily. Then, the energy absorption capability would be small. F. Other Discussion on Nonuniformity of Energy Absorption Capability From Figs. 2 and 3, when the applied current is high and the time duration is small, the scattered phenomenon of energy absorption capabilities of different ZnO varistors is not obvious, but if the applied current is low and the time duration is very long, then the scattered phenomenon of the energy absorption capabilities of different ZnO varistors would be very apparent. When the applied current is high and the time duration is small, it can be treated as a thermally insulated temperature rise process. The heat diffusion among different grains can be neglected, then the current localization is only influenced by the nonuniformity of the microstructural electrical performance. So the nonuniformity of the energy absorption capabilities is small. But if the applied current is low and the time duration is very long, the heat diffusion among different grains should be considered, then the current localization would be influenced by the nonuniformities of microstructure, electrical and thermophysical performances together. All these influential factors are nonuniform, so the deviation of the energy absorption capabilities of different ZnO varistors would be very high. The uniform current distribution shown in Fig. 7 is particularly important to varistor disk with large cross-section area, because it has higher probability of microstructural, electrical and thermophysical nonuniformities and becomes more prone to puncture and cracking. Thus, its energy absorption capability per unit volume decreases with the increase of cross-sectional area. As a further conclusion, the energy absorption capability of a ZnO varistor can be improved by reducing the current localization, which could be weakened by enhancing the uniformities of ZnO grain size and the barrier voltage of ZnO varistor, while the first method is more viable and effective comparatively. V. ANALYSIS ON NONUNIFORMITY OF ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS The microstructural nonuniformity of ZnO varistors includes the nonuniformities of electrical and thermophysical properties. The energy absorption capabilities of ZnO varistors leading to puncture and cracking destruction can be analyzed by the thermal mechanics. When an element inside a ZnO varistor absorbs energy, the thermally insulated temperature rise is expressed as where is the volume of the element, is the specific gravity, and is the specific heat constant. The specific heat constant at 20 is 498, and the specific gravity is 5600 [23]. If the temperature rises of two close elements are and respectively, a thermal stress formed between them can be calculated by (6). The critical thermal stress which causes varistor cracking is in the range between 17.2 and 48.3 MPa [24], and 17.2 MPa is selected for this analysis. Because the contact conditions between the surface of a ZnO varistor and the electrode, and the electrical characteristics among different elements in the ZnO varistor are different, the energies absorbed by different elements in the varistor vary from element to element when a current is applied to it. The energy absorption uniformity is defined as the ratio of the minimum and the maximum energies absorbed by inner elements. When, the energy absorption of a varistor is very uniform. It is found from (2) that the temperature rise of an element inside the varistor caused by absorbed impulse energy is directly determined by the heat capacity. But different region inside the ZnO varistor has different heat capacity, the heat capacity uniformity is defined as the ratio between the minimum and the maximum values of the heat capacity among all elements inside a varistor, and, respectively We define as the average value of and, so we can use and to express (7) (8)

8 1530 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 3, JULY 2007 Fig. 12. Energy absorption capability of cracking destruction P caused by the synthetical effect of energy absorption uniformity S and heat capacity uniformity B. Fig. 13. Effect of electrical property nonuniformity on the energy absorption capability P. and. When and exist, the maximum temperature difference between two elements inside the varistor would be From (6) and (9), the impulse energy absorption capability of cracking destruction per unit volume caused by the synthetical effect of the energy absorption uniformity and the heat capacity uniformity could be calculated by (9) (10) The energy absorption capability of cracking destruction caused by the synthetical effect of the energy absorption uniformity and the heat capacity uniformity is illustrated in Fig. 12. The tested actual energy absorption capabilities of the commercial ZnO varistors were in the ranges between 216 and 269 when switching impulse currents were applied. Thus, when, the energy absorption uniformity ranges from 63.0% to 68.9%; when, then is between 74.0% and 79.2%. When, of the tested varistor is in the range from 68.7% to 72.4%. So there are obvious nonuniformities in the energy absorption capabilities and in the heat capacities of ZnO varistors. The energy absorption capability is seriously affected by the nonuniformity of ZnO varistors, which would increase quickly with the nonuniformity of ZnO varistors increases. The heat capacity nonuniformity includes two aspects. Firstly, from experimental results, the thermophysical parameters and are largely determined by temperature, while is the thermal conductivity. Thus, different elements inside a varistor have different thermophysical parameters because the temperatures vary from unit to unit, due to the nonuniformity of absorbing energies by different elements. Secondly, different elements inside a varistor have different thermophysical parameters and. These nonuniformities are caused in the sample preparation and sintering processes. The electrical property nonuniformity is defined as the ratio of the area with threshold voltage decreasing 5% and the total surface area. If is equal to 0, the ZnO varistor would be very uniform. With numerical analysis, the energy absorption capability resulting from puncture destruction, when a 3-kA square-wave current is applied to a varistor, can be illustrated in Fig. 13 as a function of. The energy absorption capability is very small when the electrical characteristic is nonuniform. Eda [1] measured the distribution of the threshold voltages in ZnO varistors by applying spot electrodes on both lapped surfaces opposite each other. For a typical sample, it has a small region with lower threshold voltage than other regions by 5%, but for a less uniform sample, the region has a lower threshold voltage than the other regions by 11%. Their respective energy absorption capabilities are 117 and 128 from our analysis. VI. ESTIMATION ON NONUNIFORMITY OF ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS Mizukoshi et al. [7] analyzed the influence of nonuniformity on energy absorption capabilities of zinc oxide elements by monitoring the surface temperature distribution of ZnO varistors with an infrared radiation thermo-camera. Local heating is induced by current concentration in some portion of the varistor. The nonuniformity factor is defined as (11) where and are the maximum and minimum temperatures inside a ZnO varistor when a voltage is applied to it, and is the initial temperature. The highest reaches about 1.7. The average energy absorption capability of the uniform varistors reaches about 700, but when, the energy absorption capability is only 400. In many cases the punctured area of a varistor agrees with the hot spot in the thermograph, proving that the varistor is melt by current concentrations. When an overvoltage is applied to a ZnO varistor, the portion with the highest nonuniformity would first reach its puncture energy, and the varistor would be broken.

9 HE AND HU: DISCUSSIONS ON NONUNIFORMITY OF ENERGY ABSORPTION CAPABILITIES OF ZnO VARISTORS 1531 We measured the actual energy absorption capabilities of the commercial ZnO varistors, which were in the range from 218 to 269 when a switching impulse current was applied to them. It was only 31.1% to 38.4% of that of the uniform varistor tested by Mizukoshi et al. [7]. So there exists apparent nonuniformity existing in our measured commercial ZnO varistors. From Fig. 12, if the microstructure and the electrical and thermophysical characteristics of varistors are uniform, the energy absorption capability of this ideal ZnO varistor can reach as high as 900. Thus, the actual energy absorption capabilities of our analyzed commercial ZnO varistors is from 24.2% to 29.9% of that of the ideal uniform varistor. Therefore, it is reasonable that the energy absorption capability of a varistor decreases substantially if it has a high nonuniformity. So, to improve the uniformities of the microstructure, the electrical characteristics and thermophysical parameters of ZnO varistors would greatly increase their energy absorption capabilities, which could be improved by modifying the sintering technique and additives. In the meantime, the surface of ZnO varistor should be very plain, and good contact conditions between ZnO varistors and high voltage electrode, and among different ZnO varistors when ZnO varistors are assembled as surge arresters, should be reached. VII. CONCLUSIONS The energy absorption capabilities of commercial ZnO varistors under different impulse current waves were measured, which is directly relative to the impulse current waves. The experimental results state that the measured energy absorption capabilities are highly scattered, behaving -shape curves according to the time duration and the current density of applied impulse current. The experimental results also show that the absorbed impulse destruction energy does not increase linearly with the increment of the varistor surface area. This phenomenon is due to the nonuniformity in the microstructure of varistor and the nonuniformity of absorbed energies in different portions inside the varistor. The nonuniformity of ZnO varistors includes the nonuniformity of microstructure, and nonuniformities of electrical and thermophysical properties. The numerical simulations on microstructures of ZnO varistors explain that it is the microstructural nonuniformity of ZnO varistors that leads to current and energy concentrations, and decreases the global energy absorption capabilities. The measured actual energy absorption capabilities of the commercial ZnO varistors are only 24.2% to 29.9% of that of the ideal uniform varistors. There is a very high nonuniformity existing in the energy absorption capabilities of our measured commercial ZnO varistors. REFERENCES [1] K. 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10 1532 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 3, JULY 2007 Jin-Liang He (M 02 SM 02) was born in Changsha, China, in He received the B.Sc. degree in electrical engineering from Wuhan University of Hydraulic and Electrical Engineering, Wuhan, China, in 1988, the M.Sc. degree in electrical engineering from Chongqing University, Chongqing China, in 1991, and the Ph.D. degree in electrical engineering from Tsinghua University, Beijing, China, in Currently, he is Vice Chief of the High Voltage Research Institute at Tsinghua University, Beijing. He became a Lecturer in the Department of Electrical Engineering, Tsinghua University, in 1994, and an Associate Professor in the same department in From 1994 to 1997, he was the Head of the High Voltage Laboratory at Tsinghua University. He was also a Visiting Scientist in Korea Electrotechnology Research Institute, involved in research on metal-oxide varistors and high-voltage polymeric metal-oxide surge arresters from 1997 to In 2001, he was promoted to a Professor at Tsinghua University. His research interests include overvoltages and EMC in power systems and electronic systems, grounding technology, power apparatus, dielectric material, and power distribution automation. He is the author of four books and many technical papers. Dr. He is a Senior Member of the China Electrotechnology Society, the Vice Chief of the China Lightning Protection Standardization Technology Committee, and is the China representative of IEC TC 81. He is a member of the International Compumag Society, the IEC TC 81 Working Groups, the Electromagnetic Interference Protection Committee, the Transmission Line Committee of China Power Electric Society, the China Surge Arrester Standardization Technology Committee, the Overvoltage and Insulation Coordination Standardization Technology Committee, and the Surge Arrester Standardization Technology Committee in Electric Power Industry. He is the Chief Editor of the Journal of Lightning Protection and Standardization (in Chinese). Jun Hu was born in Ningbo City, Zhejinag Province, China, in He received the B.Sc. and M.Sc. degrees in electrical engineering in July 1998 and July 2000, respectively, from the Department of Electrical Engineering, Tsinghua University, Beijing, China, where he is currently pursuing the Ph.D. degree. His research fields include overvoltage analysis in power system and dielectric materials.

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